Internal combustion engine mufflers

ABSTRACT

A muffler is provided having a series of filter discs through which the exhaust gases may flow. These may include supporting discs of steel mesh or expanded metal, discs of corrugated asbestos coated with charcoal with the corrugated flutes extending parallel the muffler axis, discs of fiberglass impregnated with lithium hydroxide, perforated discs of coke, and combinations thereof. Blue clay may partially line the muffler body.

United States Patent [1 1 Riojas [4 1 Apr. 9, 1974 INTERNAL COMBUSTION ENGINE MUFFLERS [76] Inventor: Gregorio Riojas, 992 Argyle, St.

Paul, Minn. 55103 [22] Filed: Aug. 23, 1972 [21] Appl. No.: 283,183

[52] U.S. Cl 55/276, 55/316, 55/321, 55/418, 55/486, 55/524, 55/DIG. 30, 60/311 [51] InLCI B0ld 39/14 [58] Field of Search 55/DIG. 30, 276, 316, 387, 55/485-488, 321, 322, 524, 525; 60/311; 23/284, 285, 288 F [56] 7 References Cited UNITED STATES PATENTS 3,675,398 7/1972 Giarrizzo 55/ DIG. 30 X 821,828 5/1906 Phelps 55/DIG. 30 X 3,664,095 5/1972 Asker et al. 55/524 X 2,902,834 9/1959 Bosworth, Jr. et al 55/387 X 1,781,664 11/1930 Rockwell 55/DIG. 33 X 3,611,678 10/1971 Holden 55/387 3,593,499 7/1971 Kile 55/DIG. 30 X Primary Examiner-Frank W. Lutter Assistant Examiner-William Cuchlinski, Jr. Attorney, Agent, or Firm-Robert M. Dunning [57] ABSTRACT A muffler is provided having a series of filter discs through which the exhaust gases may flow. These may include supporting discs of steel mesh or expanded metal, discs of corrugated asbestos coated with charcoal with the corrugated flutes extending parallel the muffler axis, discs of fiberglass impregnated with lithium hydroxide, perforated discs of coke, and combinations thereof. Blue clay may partially line the muffler body.

4 Claims, 4 Drawing Figures PATENTEUAPR 9mm $802,163

INTERNAL COMBUSTION ENGINE MUFFLERS This invention relates to an improvement in Internal Combustion Engine Mufflers and deals particularly with a muffler capable of greatly reducing the carbonomonoxide and hydrocarbon content of the emitted fumes from the engine.

BACKGROUND OF THE INVENTION It is a well known fact that the fumes being emitted from an internal combustion engine such as that powering an automobile or the like contain considerable carbonmonoxide and hydrocarbon particles. During recent years the problem of air polution has been recognized to a greater and greater extent. Public sentiment against air polution has grown to the extent that at the present time the manufacturers of automobiles have been given a fixed time period to reduce the polution causing portions of the exhaust to a desired minimum.

A great number of different types of devices have been produced in an effort to meet the polution standards. Attempts are being made to burn the particles in the exhaust and to dispose of them in various ways. Numerous variations of mufflers have been produced in order to filter out the solid particles, and to reduce the earbonmonoxide content. The present invention resides in a device of this type.

SUMMARY OF THE INVENTION I have found that the impurities in the exhaust from automobile engines may be greatly reduced through the use of a muffler of my design. Tests made on vehicle engines with and without the muffler have indicated that the carbonmonoxide content of the exhaust while at idling speeds may be cut more than two-thirds, and may be cut more than half while the engine is running at 2,500 rpm. These tests also indicate that the hydrocarbon content of the exhaust fumes may be cut almost three-fourths while the engine is idling, and may be cut almost the same amount while the engine is running at 2,500 rpm. Thus the muffler has been very effective in materially reducing the air polution.

An object of the present invention resides in the provision of a muffler having a series of spaced disc-like members through which the exhaust gases must pass. In preferred form, certain of these members includes a supporting disc of steel mesh or expanded metal. A disc of asbestos having passages extending therethrough parallel to the axis of the muffler adjoins the metal disc, and is covered with charcoal. A disc of fiberglass impregnated with lithium hydroxide is provided adjoining the asbestos discs. Adjoining the fiberglass filter pad is preferably provided a disc of coke having passages extending therethrough in a direction parallel to the muffler axis. The filters formed in this manner have been found extremely effective in reducing air polution.

A feature of the present invention resides in the provision of a pad formed of asbestos and charcoal which is incorporated in the filter. This pad is comprised of a series or corrugated strips of asbestos mounted between parallel strips of asbestos. The charcoal is coated on the surface of the strips. The flutes of the corrugated layers extend parallel to the axis of the muffler, thus forming a great number of passages extending through the disc through which the exhaust gases must flow.

A further feature of the present invention resides in the provision of a layer of blue clay forming a partial liner along the bottom wall of the muffler body, this clay being of the type used to produce certain types of bricks. This clay seems a significant advantage in the effectiveness of the muffler.

A further feature of the present invention resides in the provision of lumps of coke on the clay surface.

These and other objects and novel features of the present invention will be more clearly and fully set forth in the following specification and claims.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a vertical sectional view longitudinally through the muffler showing the general arrangement of parts therein.

FIG. 2 is an enlarged sectional view through one of the filter discs, showing the general arrangement of parts therein.

FIG. 3 is a partial end view of one of the perforated coke discs.

FIG. 4 is a partial end view of the asbestos-charcoal discs.

DESCRIPTION OF THE PREFERRED EMBODIMENT The muffler is indicated in general by the letter A. It comprises an elongated cylindrical tube 10 having a circular end plate 11 at one end thereof. The periphery of the plate 11 is grooved to accommodate one end of the sleeve 10, forming a crimped edge 12 An inlet 13 is provided on the end plate 11, preferably near the lower end thereof. A baffle plate 14 is provided with a cylindrical flange 15 which. fits snugly within the seeeve 10 and which is provided with an inturned flange 16 secured to the end plate 1 l. The baffle 14 is provided with an outlet opening 17 which is near the upper edge of the baffle. In any event, the inlet 13 and outlet 17 are arranged on opposite sides of the muffler axis to change the direction of flow of the gases entering the muffler body.

A series of filter members 19, 20, 21 and 22 extend across the muffler body as indicated in FIG. 1. The discs are held in place by welding the metal portions of the same to the muffler sleeve, or may be fastened in any other suitable manner. The various filter discs are in spaced relation as indicated.

An end plate 23 similar to the end plate 11 closes the outlet end of the muffler. The closure plate 23 is provided with a grooved and crimped marginal edge 24 which secures it to the sleeve 10. A baffle 25, similar to the baffle I4, is provided with a peripheral flange 26 terminating in an inturned flange 27 by means of which the baffle plate 25 is secured in spaced relation to the end plate 23 by welding or other suitable means. The end plate 23 is provided with an outlet conduit 29, and the baffle 25 is provided with an outlet sleeve'30, the passages 29 and 30 being on opposite sides of the axis of the sleeve 10. In the particular arrangement illustrated, the passage 30 near the lower edge of the mufflcr while the passage 29 is near the upper edge of the end plate 23.

The filter plates 19 and 20 are preferably formed in the manner illustrated diagramatically in FIG. 2 of the drawings. The numeral 31 indicates. a disc of steel mesh or expanded metal, and this disc may if desired have a peripheral flange which is anchored to the muffler sleeve 10. Adjoining the disc 31 is a. filter disc 32 which is shown more in detail in FIG. 4 of the drawings. As

indicated in this figure, the disc 32 includes corrugated layers, or strips 33 of asbestos which are secured between parallel layers or strips 34 of the same material. In other words, the discs are formed similarly to multiwall corrugated paperboard with the flutes of the corrugated strips 33 extending parallel to the longitudinal axis of the muffler. This arrangement provides a great number of passages 35 extending through the discs through which the gases flow. The corrugated asbestos is coated with pulverized charcoal mixed with a suitable binder capable of securing the particles of charcoal to the asbestos,the coating completely lining the walls of the passages through the asbestos disc.

Adjoining each of the discs 32 a disc or pad 36 of fiberglass or similar material, capable of withstanding the temperatures to which it is subjected-The filters 19 and are completed by discs 37 formed of coke and having passages 39 extending therethrough which are parallel to the muffler axis. These passages 39 may extend on concentric rings about the axis of the disc or may be otherwise arranged to provide adequate flow for the gases.

The discs 21 and 22 are preferably similar to the discs 19 and 20 which have been described with the exception of the fact that the charcoal discs are omitted from the combination. The various elements of the disc are held together by adhesive material capable of withstanding the temperatures involved. In the preferred form of the muffler, a layer or blue clay 40 is provided, normally throughout the length of the muffler between the various partitions 14 and and partially lining the muffler body. In some instances lumps of coke such as 41 are provided resting upon the clay 40 between certain of the filter pads, as for example, between the discs 19 and 20, and between the discs 20 and 21. The resultant muffler has proven very effective in reducing the emission of carbon monoxide and hydro-carbon from the muffler outlet.

In a test conducted by the Galaxy Auto Center in Saint Paul, Minnesota, various measurements were made to determine the extent of the polution emitting from certain cars. In general, cars were chosen which were several years old and which emitted visible exhaust fumes. In the last test which was made, the exhaust issuing from the exhaust pipe without the present muffler showed a carbonmonoxide content of 7.9 percent at idling speed and a hydrocarbon content of 1,500 pp million. At 2,500 rpm. the carbon monoxide was of 1 percent content and the hydrocarbon content was 1,150 pp million.

When the present muffler was used, at idling speed the carbon monoxide content of the emitted gases was reduced to 2.5 percent, and the gydrocarbon content was dropped to 390 pp million. At 2,500 rpm. the carbon monoxide content was reduced to 0.4 percent and the hydrocarbon content was reduced to 385 pp million. Thus a very marked reduction in the carbon monoxide and hydrocarbon content was obtained.

In accordance with the Patent Statutes, l have described the principles of construction and operation of my muffler and while I have endeavored to set forth the best embodiment thereof, I desire to have it understood that changes may be made within the scope of the following claims without departing from the spirit of my invention.

I claim:

1. A muffler having an elongated tubular body,

end closures closing each end of said tubular body, each end closure comprising a chamber having non-aligned inlet and exit apertures through which exhaust gases may flow,

a plurality of disc shaped filter members extending in spaced relationship across said tubular body so that exhaust gases flow therethrough, each filter member comprising from the upstream to the downstream side respectively a metal mesh layer, a layer of corrugated strips of asbestos secured between parallel strips of asbestos, the flutes of said corrugated strips being generally parallel to the longitudinal axis of said tubular body, said strips of asbestos being coated with charcoal, and a layer of lithium hydroxide impregnated fiberglass pad.

2. The muffler of claim 1 in which said filter members also include a perforated coke disc on the downstream side.

3. The muffler of claim 2 including a lining of clay on a portion of the inside wall of said tubular body adjacent said filter members.

4. The muffler of claim 3 including a plurality of lumps of coke resting upon said clay lining. 

1. A muffler having an elongated tubular body, end closures closing each end of said tubular body, each end closure comprising a chamber having non-aligned inlet and exit apertures through which exhaust gases may flow, a plurality of disc shaped filter members extending in spaced relationship across said tubular body so that exhaust gases flow therethrough, each filter member comprising from the upstream to the downstream side respectively a metal mesh layer, a layer of corrugated strips of asbestos secured between parallel strips of asbestos, the flutes of said corrugated strips being generally parallel to the longitudinal axis of said tubular body, said strips of asbestos being coated with charcoal, and a layer of lithium hydroxide impregnated fiberglass pad.
 2. The muffler of claim 1 in which said filter members also include A perforated coke disc on the downstream side.
 3. The muffler of claim 2 including a lining of clay on a portion of the inside wall of said tubular body adjacent said filter members.
 4. The muffler of claim 3 including a plurality of lumps of coke resting upon said clay lining. 